Screw with breakaway and methods of using the same

ABSTRACT

A fastener with a breakaway and methods of using the same. In one embodiment the fastener is a screw having a head and elongated stem, adapted to be easily manipulated by a user when using the screw as a fastener in a hinge or joint. A means of holding a screw by providing a breakaway tab or non-threaded portion of the elongated stem which can be used to align and insert the screw into a screw hole in the process of engaging threads in the screw hole with threads of the screw. After engaging the threads in the screw hole, such as after the screw has been essentially completely inserted into the screw hole, the breakaway tab or non-threaded portion of the elongated stem of the screw may be broken off at a breakaway and discarded.

The present patent application is a division application of non-provisional application Ser. No. 12/187,254, which claims priority from provisional applications with Ser. Nos. 60/963,519 (filed Aug. 6, 2007 and titled “IBOB (Specialize Screw)”) and 60/993,726 (filed Sep. 14, 2007 and titled “IBOB”).

FIELD OF THE INVENTION

The present invention relates generally to fasteners. More specifically, the invention relates to screws and their use in joints.

BACKGROUND

Small, hand held fastening devices are used in the mechanical and construction industries.

There is an increasing need for adaptations that facilitate the manipulation of such small, hand held fastening devices.

SUMMARY OF THE INVENTION

A first aspect of the present invention provides a screw, comprising: a screw head, comprising: a first surface having a driver slot thereon, and a second surface, wherein the second surface of the screw head faces away from the first surface; an elongated stem, comprising: either a threaded first portion and a non-threaded second portion extending from the distal end of the threaded first portion and a first breakaway therebetween, wherein a proximal end of the threaded first portion is mechanically and physically coupled to the second surface of the screw head, wherein the physical coupling between the second surface of the screw head and the proximal end of the threaded first portion is not a breakaway, wherein the first breakaway releasably couples the non-threaded second portion to the distal end of the threaded first portion, or a threaded first portion, without the non-threaded second portion extending from the threaded first portion and a second breakaway, wherein a proximal end of the threaded first portion is non-releasably mechanically and physically coupled to the second surface of the screw head, wherein the mechanical and physical coupling between the second surface of the screw head and the proximal end of the threaded first portion is not a breakaway, and wherein the second breakaway releasably couples the first surface of the screw head to a breakaway tab.

A second aspect of the present invention provides a method of replacing a screw in a hinge, comprising: providing a hinge, comprising: first and second straps, pivotably coupled to a cylinder, wherein the cylinder has a threaded hollow channel therein; providing a screw comprising: a head; an elongated stem comprising: either a threaded first portion adjacent to the head; and a non-threaded second portion extending from the threaded first portion; and a first breakaway therebetween, wherein the first breakaway releasably couples the non-threaded second portion to the distal end of the threaded first portion, or a threaded first portion adjacent to the head without the non-threaded second portion extending from the threaded first portion and a second breakaway, wherein the second breakaway releasably couples the first surface of the screw head to a breakaway tab; inserting the non-threaded second portion of the elongated stem into the hollow threaded channel in the hinge so that the non-threaded second portion of the elongated stem extends out of the hollow threaded channel of the hinge; or inserting the threaded portion of the elongated stem into the hollow threaded channel in the hinge by a user manipulating the insertion using the breakaway tab; aligning the threaded first portion of the elongated stem with the threads of the hollow threaded channel of the hinge; and screwing the first threaded portion of the elongated stem into the hollow threaded channel of the hinge by rotating the threaded first portion of the elongated stem that has been aligned with the threads of the threaded hollow channel of the hinge.

A third aspect of the present invention provides a kit, comprising: a hinge, comprising first and second straps, pivotably coupled to a cylinder, wherein the cylinder has a threaded hollow channel therein; a screw, comprising: a head; an elongated stem, comprising: either a threaded first portion adjacent to the head and a non-threaded second portion extending from the threaded first portion and a first breakaway therebetween, wherein the first breakaway releasably couples the first threaded portion of the elongated stem to the non-threaded second portion of the elongated stem, wherein the non-threaded second portion of the elongated stem has been aligned with the hollow threaded channel in the hinge, and wherein the non-threaded second portion of the elongated stem has been inserted into the hollow threaded channel in the hinge so that the threaded first portion of the elongated stem catches at least one of the threads of the hollow threaded channel of the hinge; or a threaded first portion physically and mechanically non-releasably coupled to the second surface of the screw head without the non-threaded second portion extending from the threaded first portion and a second breakaway, wherein the second breakaway releasably couples the first surface of the screw head to a breakaway tab, wherein the proximal end of the threaded portion and the second surface of the screw head are non-releasably coupled, and wherein the threaded first portion of the elongated stem has caught at least one thread of the hollow threaded channel of the hinge, by threading the threads of the first portion of the elongated stem with the threads of the hollow threaded channel.

A fourth aspect of the present invention provides a system for guiding a screw into a hinge, comprising: a hinge, wherein the hinge has a hollow channel therein; a screw, comprising: a head; an elongated stem, comprising: a threaded first portion adjacent to the head; and a non-threaded second portion extending from the threaded first portion; and a breakaway, wherein the breakaway is removably connected therebetween or removably connected to the first surface of the screw head, but the breakaway is not removably connected between the threaded first portion of the elongated stem and the head of the screw, wherein the non-threaded second portion of the elongated stem has been aligned with the hollow threaded channel in the hinge, wherein the non-threaded second portion of the elongated stem has been manipulated into the threaded hole in the hinge so that the threaded first portion of the elongated stem is articulated with the threads of the hollow threaded channel of the hinge, and wherein the screw has been inserted into the threaded first portion of the elongated stem by threading the threads of the first portion of the elongated stem with the threads of the threaded hole.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A depicts a top plan view of a first surface of a screw head of a screw, in accordance with embodiments of the present invention;

FIG. 1B depicts a longitudinal cross-sectional view of the screw depicted in FIG. 1A, in accordance with embodiments of the present invention;

FIG. 2A depicts a front longitudinal view of a screw, in accordance with embodiments of the present invention;

FIG. 2B depicts a top plan view of a first surface of a screw head of the screw depicted in FIG. 2A, in accordance with embodiments of the present invention;

FIG. 3A depicts a side elevation view of the screw the screw depicted in FIGS. 2A and 2B, in accordance with embodiments of the present invention;

FIG. 3B depicts a top plan view of a first surface of a screw head of the screw depicted in FIGS. 2A, 2B, and 3A, in accordance with embodiments of the present invention;

FIG. 4 depicts a longitudinal cross-sectional view of a kit, in accordance with embodiments of the present invention;

FIG. 5 depicts a top plan view of a screw having a screw head, in accordance with embodiments of the present invention; and

FIGS. 6A-6C depict a flow diagram of a method of replacing a screw in a hinge of the kit, depicted in FIG. 4, in accordance with embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

FIG. 1A depicts a top plan view of a first surface 19 of a screw head 15 of a screw 10. The screw head 15 includes a driver slot 17. The screw 10 may be a round head 15 made of stainless steel, brass, nickel/sliver, carbon steel, titanium, or other appropriate metals or metal alloys. The driver slot 17 may be a single groove, a Phillips® cross shaped groove, an hexagonal groove for turning with a hex wrench.

FIG. 1B depicts a longitudinal cross-sectional view of the screw 10. The screw 10, comprises: the screw head 15, comprising: a first surface 19 having a driver slot 17 thereon, and a second surface 18, wherein the second surface 18 of the screw head 15 faces away from the first surface 19. The screw 10 comprises an elongated stem 11. The elongated stem 11 comprises a threaded first portion 20. A proximal end A of the threaded first portion 20 is mechanically and physically coupled to the second surface 18 of the screw head 15. The mechanical and physical coupling between the second surface 18 of the screw head 15 and the proximal end A of the threaded first portion 20 is not a breakaway 25, 43. The elongated stem 11 comprises a non-threaded second portion 30 extending from a distal end C of the threaded first portion 20; and a breakaway 25 therebetween.

Hereinafter, a “breakaway” is defined as a releasable coupling between a removable piece such as the proximal end 12 of the non-threaded second portion 30 and the distal end C of the threaded first portion 20. Hereinafter, “distal end” is defined as the further point along the elongated stem 11 in reference to the second surface 18 of the screw head 15, and “proximal” is defined as the nearer point along the elongated stem 11 in reference to the second surface 18 of the screw head 15.

Hereinafter “releasably coupling” is defined as forming or braking or cleaving or severing a mechanical and physical coupling between the removable piece such as the proximal end 12 of the non-threaded second portion 30 and the distal end C of the threaded first portion 20.

Hereinafter “screwing the screw 10, 13 into a screw hole 59, 100 or threaded hollow channel of a hinge 64” is defined as engaging the threads 63 in the screw hole 59, 100 or hollow threaded channel 64 of a hinge 66, by rotating the screw 10, 13 about its longitudinal axis in a clockwise motion, resulting in the screw 10, 13 being essentially completely inserted into the screw hole 59, 100 or hollow threaded channel 64 of the hinge 66. Such engaging the threads 63 in the screw hole or hollow threaded channel 64 has the ultimate end that the screw 10, 13 has been essentially completely inserted into the screw hole 59, 100.

In one embodiment, the screw 10 comprises a non-threaded first portion 30 for making it easier to handle the screw 10. You insert the non-threaded first portion 30 of the screw 10 into a screw hole 100 first and then you are able to pull the threaded second portion 30 of the screw 10 into the screw hole 100 as the non-threaded second portion 30 is removed from the screw hole 100. This adapts the screw 10 to be more easily manipulated by hand by a user.

In one embodiment, a length L₁ from about 0.3375 in. to about 0.4125 in. may separate the proximal end A of the threaded first portion 20 and the distal end C of the threaded first portion 20.

In one embodiment, a length L₂ from about 0.6973 in. to about 0.8525 in. may separate the proximal end A of the threaded first portion 20 and the distal end B of the non-threaded second portion 30 of the elongated stem 11.

In one embodiment, a diameter W₃ of the non-threaded second portion is preferably smaller than a diameter W₂ of the threaded first portion 20 of the elongated stem 11. In one embodiment the diameter W₃ is from about 0.036 in. to about 0.044 in.

FIG. 2A depicts a front longitudinal view of a screw 13. The screw 13 comprises: a screw head 50 and an elongated stem 14. The screw head 50, comprises: a first surface 44 having a driver slot 51 thereon. The screw head 50, comprises a second surface 48, depicted in FIG. 3A and described in associated text. The second surface 48 of the screw head 50 faces away from the first surface 44. The elongated stem 14, comprises: either a threaded first portion 20 and a non-threaded second portion 30 extending from the distal end C of the threaded first portion 20 and a first breakaway 25 therebetween, depicted in FIG. 1B, or a threaded first portion 42, without the non-threaded second portion 30, depicted in FIG. 1B, extending from the threaded first portion 42 and a second breakaway 43. A proximal end E of the threaded first portion 42 is non-releasably coupled to the second surface 48 of the screw head 50. The mechanical and physical coupling between the second surface 48 of the screw head 50 and the proximal end E of the threaded first portion 42 is not a breakaway 25, 43. In this embodiment, the first breakaway 25 releasably couples the non-threaded second portion 30 to the distal end C of the threaded first portion 20.

In an alternative embodiment the threaded first portion 20, without the non-threaded second portion 30 extends from the threaded first portion 20 and a second breakaway 43. In this embodiment, a proximal end E of the threaded first portion 20 is non-releasably mechanically and physically coupled to the second surface 48 of the screw head 50. In this embodiment, the mechanical and physical coupling between the second surface 48 of the screw head 50 and the proximal end E of the threaded first portion 20 is not a breakaway 25, 43. In addition, the second breakaway 43 releasably couples the first surface 48 of the screw head 50 to a breakaway tab 45.

In one embodiment, a screw 13 with a break away tab 45 on the screw head 50 guides screws 13 into a screw hole for easy maneuverability. Any size screw 13, or break away tab 45 may be placed anywhere on the head 50 of the screw 13. Insert the screw 13 in hole 59, turn the break away tab 45 to start the screwing operation and then break the break away tab 45 off.

In one embodiment, a length L₅ from the second surface 48 to the second breakaway 43, releasably coupling the breakaway tab 45, may be from about 0.1 in. to about 0.21 in.

In one embodiment, a width W₇ of the breakaway tab 45 may be from about 0.225 in. to about 0.275 in. and a length L₃ of the breakaway tab 45 may be from about 0.45 in. to about 0.55 in.

FIG. 2B depicts a top plan view of a first surface 44 of a screw head 50 of the screw 13. The screw head 50 includes a driver slot 51. The screw 13 may be made of stainless steel, brass, nickel/sliver, carbon steel, titanium, or other appropriate metals or metal alloys. The driver slot 51 may be a single groove, a Phillips® cross shaped groove, or an hexagonal groove for turning with a hex wrench.

FIG. 3A depicts a side elevation view of the screw 13. In one embodiment, a length L₄ from the proximal end E of the threaded first portion 20 to the distal end F of the threaded first portion of the elongated stem 14 may be from about 0.3942 in. to about 0.4818 in.

In one embodiment, a face 49 of the breakaway tab 45 and a longitudinal plane of the driver slot 51 are parallel. A width W₈ of the driver slot 51 may be from about 0.045 in. to about 0.055 in. A ratio of the thickness L₉ of the breakaway tab 45 of the screw 13 to the width W₈ of the driver slot 51 is from about 0.3:1.0 to about 0.4:0.9.

In one embodiment, a ratio of the length L₁ of the threaded first portion 20 to the non-threaded second portion 30 of the screw 10 is from about 1:1 to about 0.775:1.

In one embodiment, a diameter of the first breakaway 25 of the screw 10 is less than or equal to 0.015 in., when the diameter of the elongated stem 11 is essentially equal to 0.040 in.

In one embodiment, a ratio of the width W₁ of the breakaway tab 45 to a length L₃ of the breakaway tab 45 is from about 1:2 to about 1:10.

In one embodiment, the screw head 50 is a slotted undercut oval countersunk head.

In one embodiment, the threaded first portion 42 has a 6-32 UNF thread, wherein conventional UNC or UNF thread is a 60 degree thread.

In one embodiment, a ratio of the length L₄ of the threaded first portion 42 to the length L₃ of the breakaway tab 45 of the screw 10 is from about 1:1 to about 0.876:1.

FIG. 3B depicts a top plan view of a first surface 44 of a screw head 51 of the screw 50. In one embodiment, a width W₁ of the second breakaway 43 across the first surface 44 of the screw head 50, depicted in FIG. 2B, is from about 75% to about 95% of the length L₁₀ of the driver slot 51 thereon.

FIG. 4 depicts a longitudinal cross-sectional view of a kit 65. In one embodiment, the kit 65 comprises: a hinge 66, comprising first and second straps 60, 61, pivotably coupled to a cylinder 62. The cylinder 62 has a hollow threaded channel 64 therein. The kit 65 comprises: a screw 10, comprising: a head 19 and an elongated stem 11. The elongated stem 11, comprises: either a threaded first portion 20 adjacent to the head 15 and a non-threaded second portion 30 extending from the threaded first portion 20 and a first breakaway 25 therebetween. The first breakaway 25 releasably couples the threaded first portion 20 of the elongated stem 11 to the non-threaded second portion 30 of the elongated stem 11. The non-threaded second portion 30 of the elongated stem 11 has been aligned with the hollow threaded channel 64 in the hinge 66. The non-threaded second portion 30 of the elongated stem 11 has been inserted into the hollow threaded channel 64 in the hinge 66 so that the threaded first portion 20 of the elongated stem 11 catches at least one of the threads 63 of the hollow threaded channel 64 of the hinge 66.

Alternatively, the kit 65 comprises; a screw 13, depicted in FIGS. 2A, 2B, and FIGS. 3A, 3B. The screw 13 comprises: a screw head 50 and an elongated stem 14.

The elongated stem 14 comprises a threaded first portion 42 physically and mechanically non-releasably coupled to the second surface 48 of the screw head 50 without the non-threaded second portion 30, depicted in FIGS. 1A, B extending from the threaded first portion 42 and a second breakaway 43. The second breakaway 43 releasably couples the first surface 44 of the screw head 50 to a breakaway tab 45. The threaded first portion 42 of the elongated stem 11 has caught at least one thread 63 of the hollow threaded channel 64 of the hinge 66, by threading the threads 67 of the threaded first portion 20 of the elongated stem 11 with the threads 63 of the hollow threaded channel 64.

In all preferred embodiments, the proximal end E of the threaded first portion 42 and the second surface 48 of the screw head 50 are mechanically and physically non-releasably coupled.

In one embodiment, the breakaway tab 45 extends along a longitudinal axis of the screw 13, away from the first surface 44 of the screw head 50.

FIG. 5 depicts a top plan view of a screw 85 having a screw head 86. The screw head 86 has a first surface 80 and a driver slot 81, therein. The screw head 86 is releasably coupled to a breakaway tab 84, having a breakaway 83 therebetween. The breakaway tab 84 has a first surface 79, and the first surface 79 may be coplanar with the first surface 80 of the screw head 86.

FIGS. 6A-6C depict a flow diagram of a method 90 of replacing a screw 10, 13 in a hinge 66, depicted in FIG. 4, and described in associated text and depicted in FIGS. 2A-3B, and described in associated text. In a step 92 of the method 90, a hinge 66 is provided. In the step 92 of providing the hinge 66, first and second straps 60, 61 may be pivotably coupled to a cylinder 62. The cylinder 62 has a hollow threaded channel 64 therein;

In a steps 96 and 98 a screw 10, 13 is provided. The screw 10, 13 comprises: a head 15, 50; an elongated stem 11,14.

In the steps 96, 98 the elongated stem 11, 14 comprises: either a threaded first portion 20, 42 adjacent to the head 15, 50; and a non-threaded second portion 30, extending from the threaded first portion 20, 42; and a first breakaway 25 therebetween, wherein the first breakaway 25 releasably couples the non-threaded second portion 30 to the distal end C of the threaded first portion 20, or a threaded first portion 42 adjacent to the head 50 without the non-threaded second portion 30 extending from the threaded first portion 42 and a second breakaway 43, wherein the second breakaway 43 releasably couples the first surface 44 of the screw head 50 to a breakaway tab 45;

In a step 100 of the method 90, the non-threaded second portion 30 of the elongated stem 11 may be inserted into the hollow threaded channel 64 in the hinge 66 so that the non-threaded second portion 30 of the elongated stem 11 extends out of the hollow threaded channel 64 of the hinge 66.

Alternatively, in the step 102 of the method 90, the threaded first portion 42 of the elongated stem 14 may be inserted into the hollow threaded channel 64 in the hinge 66 by a user manipulating the insertion using the breakaway tab 45.

In a step 104 of the method 90, the threaded first portion 20, 42 of the elongated stem 11, 14 may be aligned with the threads 63 of the hollow threaded channel 64 of the hinge 66.

In a step 106 of the method 90, the first threaded portion 20, 42 of the elongated stem 11, 14 may be screwed into the hollow threaded channel 64 of the hinge 66 by rotating the threaded first portion 20, 42 of the elongated stem 11, 14 that has been aligned with the threads 63 of the threaded hollow channel 64 of the hinge 66.

In one embodiment of the step 102 of the method 90, the breakaway tab 45 extends along a longitudinal axis of the screw 13, away from the first surface 44 of the screw head 50.

In one embodiment of the step 102 of the method 90, a first surface 79 of the breakaway tab 84 and a first surface 80 of the screw head 86 are coplanar, depicted in FIG. 5, and described in associated text.

In one embodiment of the step 106 of the method 90, a user may turn the breakaway tab 45 about its longitudinal axis to rotate the screw 13, wherein the breakaway tab 45 is releasably coupled to the first surface 44 of the screw head 50 by the second breakaway 43.

In one embodiment of the step 106 of the method 90, the breakaway tab 45, 84 is broken off from the first surface 44 of the screw head 50 at the second breakaway 43, or at the second breakaway 83, after the threaded first portion 42 of the elongated stem 14 catches at least one thread 63 of the threaded hollow channel 64 of the hinge 66.

In one embodiment of the step 106 of the method 90, the non-threaded second portion 30 of the elongated stem 11 is broken off at the first breakaway 25 from the threaded first portion 20 of the elongated stem 11 after the threaded first portion 20 of the elongated stem is essentially completely screwed into the threaded hollow channel 64 of the hinge 66.

In one embodiment of the step 102 of the method 90, inserting the non-threaded second portion 30 of the elongated stem 11 into the hollow threaded channel 64 in the hinge 66 so that the non-threaded second portion 30 of the elongated stem 11 extends out of the hollow threaded channel 64 of the hinge 66, by a user pulling the non-threaded second portion 30 of the elongated stem 11.

In one embodiment of the step 106 of the method 90, a user removes the non-threaded second portion 30 from the elongated stem 11 of the screw 10 after catching at least one thread 63 of the hollow threaded channel 64 of the hinge 66.

one embodiment of the step 106 of the method 90, the breakaway tab 45 extends along a longitudinal axis of the screw 13, away from the first surface 44 of the screw head 50 when the breakaway tab 45 is broken off from the first surface 44 of the screw head 50 at the second breakaway 43, after the threaded first portion 42 of the elongated stem 14 catches at least one thread 63 of the threaded hollow channel 64 of the hinge 66.

The description of the embodiments of the present invention is given above for the understanding of the present invention. It will be understood that the invention is not limited to the particular embodiments described herein, but is capable of various modifications, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, it is intended that the following claims cover all such modifications and changes as fall within the true spirit and scope of the invention. 

I claim:
 1. A method of inserting a screw into a threaded screw hole (100), comprising: providing a screw comprising: a head; an elongated stem, comprising: a threaded first portion (20) having a proximal end adjacent to the head; a non-threaded second portion (30) extending from the threaded first portion (20); and a breakaway (25) therebetween, wherein the breakaway (25) releasably couples the non-threaded second portion (30) to the distal end (C) of the threaded first portion (20), said second portion (30) having a length (L2−L1) greater than a length (L1) of the threaded first portion (20), said second portion (30) having a diameter (W3) smaller than a diameter (W2) of the threaded first portion (20) along the length (L2−L1); inserting the screw into a threaded screw hole (100) by manipulating the non-threaded second portion (30) of the elongated stem (11) by a user by hand without the use of a tool, wherein at least one thread (67) of the threaded first portion (20) engages at least one thread of the threaded screw hole (100), and wherein at least a distal end (B) of the non-threaded second portion (30) of the elongated stem (11) extends out of the threaded screw hole (100); screwing the screw (10) into the threaded screw hole (100); and removing the non-threaded second portion (30) on complete insertion of the screw (10) into the threaded screw hole (100) by manipulating the non-threaded second portion (30) of the elongated stem (11) by the user by hand without the use of a tool, resulting in breaking or cleaving the breakaway (25).
 2. The method of claim 1, wherein a ratio of the length of the threaded first portion to the non-threaded second portion is from about 1:1 to about 0.775:1.
 3. The method of claim 1, comprising the step of providing a hinge comprising first and second straps (60, 61) pivotably coupled to a cylinder (62) having a hollow threaded channel (64) therein, said hollow threaded channel being said threaded screw hole.
 4. The method of claim 3, wherein the hinge is of metal or alloy.
 5. The method of claim 3, wherein the hinge is of stainless steel.
 6. The method of claim 3, wherein the hinge is of carbon steel, brass, nickel silver or titanium.
 7. The method of claim 1, wherein the length of the first threaded portion is from about 0.3375 in. to about 0.4125 in. (8.6-10.5 mm) and the length of the second non-threaded portion is from about 0.6973 in. to about 0.8525 in. (18-21.7 mm). 